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BDIExpress Knowledge Base
Metals -- Steel / Aluminum / Foundry - Industry Articles
Saving Time and Costs by Having a Bearing Replaced by an Expert - 5310
Viewed 112 time(s) since Aug 15, 2018 - Bearings
At the Jamshedpur plant, the company has three converters. All of them had to be modernised. During the overhauling of converter 2 also its volume inside its brick lining should be increased to 153 m3, increasing its output from 140 to 170 tons of li... Read More
Reliable Brass Worm Gear Monitoring - 5308
Viewed 98 time(s) since Aug 15, 2018 - Bearings
Welded Tube’s metal tube forming line consists of four sections: forming, finishing, sizing and squaring. In the first three sections, only one electric motor drives 3 to 4 gearboxes. In its Concord plant, Welded Tube wanted to introduce predic... Read More
Mounting Service at a Wire Mill Reduces Downtime Costs - 5305
Viewed 81 time(s) since Aug 15, 2018 - Bearings
When the customer called Schaeffler, the company had an unplanned shutdown of its wire mill due to damaged bearings. These bearings had been mounted by the customer’s staff just two weeks before. By comparison, the original bearings being insta... Read More
Modernization of Four-high Heavy-plate Mill Back-up Rolls - 5304
Viewed 83 time(s) since Aug 15, 2018 - Bearings
At the beginning of 2012, SMS group GmbH received an order from the high performance alloy company VDM Metals GmbH, which produces plates and sheets in Siegen, Germany. The intention was to replace the old plate mill from 1954 with a modern version c... Read More
Modal Analysis Helps to Increase Speed of Stretch Reducing Mill - 5303
Viewed 81 time(s) since Aug 15, 2018 - Bearings
The customer had invested about 80 million euro in its production process with the objective to install a new pipe reduction gear on its main reduction stand. However, for unknown reasons he was unable to increase the machine speed beyond 80 percent ... Read More
FAG ProCheck Increased Availability of Stretch Reducing Mill - 5300
Viewed 80 time(s) since Aug 15, 2018 - Bearings
Thanks to a service contract with Schaeffler based on offline vibration analysis some chronic damage had been detected in the tandem motor bearings of the customer‘s hot strip mill. Schaeffler had determined that these damages were caused by cu... Read More
Condition Monitoring on a Hot Strip Mill - 5296
Viewed 86 time(s) since Aug 15, 2018 - Electrical, Mechanical Power Transmission
The weak spot of the rolling stands in any hot strip mill are the roller bearings on the work rollers. Under extreme operating conditions only relatively short stoppage times are possible. Unplanned stoppages and expensive consequential damage, such ... Read More
Condition Monitoring of Saw Gearboxes Increases Availability - 5295
Viewed 85 time(s) since Aug 15, 2018 - Electrical, Mechanical Power Transmission
The cutting saws of two different lines are driven by a gear motor system that at the same time drives a cutting disc. The saw drive supports the dynamic forces of the process. Due to the operating conditions it is exposed to an increased danger of w... Read More
Advanced Bearing Solutions-Steel & Non-Ferrous Metals - 5293
Viewed 42 time(s) since Aug 15, 2018 - Bearings
Tata Steel Port Talbot has two BOS steelmaking vessels (V1 & V2) in operation. The main trunnion bearings on a BOS (Basic Oxygen Steelmaking) plant at Tata Steel Port Talbot had to be replaced due to a sudden bearing failure on the nondrive side ... Read More
Air Recirculation Fan Chewing Through Bearings - 5232
Viewed 71 time(s) since Jul 30, 2018 - Bearings
A customer experienced bearing failure on an Air Recirculation Fan application within an ore preparation plant. This had been a regular problem. Compressed air cooling was applied to try and reduce the bearings high running temperature. NSK Engineers... Read More
Mounting NSK Bearings Inside a Gearbox - 5231
Viewed 72 time(s) since Jul 30, 2018 - Bearings
A steel mill planned to mount NSK bearings inside a huge gearbox for the first time. Test rig trials detected higher noise during running compared to the original design. A vibration analysis was conducted, but no clear results were reached. The cust... Read More
Cold Form Saw wasn’t Cutting Steel - 5230
Viewed 73 time(s) since Jul 30, 2018 - Bearings
A Global Steel Company was having problems with a cold form saw used to cut steel tube. The saw moved axially using a ball screw and was being supported by a simple thrust ball bearing which was failing every 6 weeks. Failures caused unplanned mainte... Read More
Dissatisfied with Steel Producer’s Bearings - 5229
Viewed 66 time(s) since Jul 30, 2018 - Bearings
A major steel producer wasn’t satisfied with the performance of their four-row tapered roller bearings installed in the cold rolling mill. Steel shavings from the production process were entering the bearings resulting in a detrimental effect o... Read More
Cold Rolling Mill was Having Bearing Failures - 5228
Viewed 53 time(s) since Jul 30, 2018 - Bearings
A steel manufacturer was experiencing continued failures of bearings on their Cold Rolling Mill. NSK engineers conducted an application review and found the highly contaminated operating conditions were causing the unexpected failures. This resulted ... Read More
Unplanned Downtime Solved at Steel Works - 5227
Viewed 70 time(s) since Jul 30, 2018 - Bearings
The continuous annealing process line at a steel works was experiencing unplanned downtime which was, on average, 17 hours per year at a cost of $23,488 per hour. Stoppages required hiring of heavy lifting gear and increased maintenance personnel. NS... Read More
Steel Manufacturer Bearings Used to Fail - 5226
Viewed 60 time(s) since Jul 30, 2018 - Bearings
An international steel manufacturer experienced regular failures on bearings in a continuous casting machine. The machine is used in the production of shaped sections and due to that, the bearings have to handle heavy loads. Wear and fatigue were res... Read More
Continuous Casting Machine Couldn’t Keep Up - 5225
Viewed 83 time(s) since Jul 30, 2018 - Bearings
A steel maker was experiencing problems with their continuous casting machine. The life of a Cylindrical Roller Bearing mounted on a continuous cast roller was only about one to two months. The casting machine had a very complicated cooling and lubri... Read More
Dust Extraction Fan Experiencing High Temperatures - 5224
Viewed 57 time(s) since Jul 30, 2018 - Bearings
An ore preparation plant was experiencing high temperatures within a dust extraction fan. The bearing temperature was cooled down at considerable cost by using compressed air. NSK Engineering carried out an Application Review including a temperature ... Read More
Regular Failures at Ore Preparation Plant Solved - 5223
Viewed 45 time(s) since Jul 30, 2018 - Bearings
A steel manufacturer was experiencing regular failures within its Ore Preparation Plant (OPP). The plant utilized housed bearing units installed on a 60mm shaft and ran at approximately 1485 rpm. NSK was informed that the bearing used was failing and... Read More
Casting Of Gas Turbine Blades Were Having Short Bearing Life - 5222
Viewed 38 time(s) since Jul 30, 2018 - Bearings
A company was experiencing short service life on bearings used in the casting of gas turbine blades. NSK conducted an Application Review of the existing design which included an inspection of the failed bearings. An extremely caustic solution combine... Read More
Hot Strip Mill is Stripping Through Bearings - 5221
Viewed 52 time(s) since Jul 30, 2018 - Bearings
A large steel manufacturer wanted to increase replacement intervals of a 4-row Tapered Roller Bearings used in the hot strip mill. Due to severe operation conditions, standard bearings provided only 1,400 hours of operation. The key target was to dec... Read More
Pilger Mill Bearing Failures - 5220
Viewed 56 time(s) since Jul 30, 2018 - Bearings
A Steel Mill customer was experiencing regular failures on bearings in their Pilger Mill. NSK investigated the application and found that severe operating conditions including high loads and inadequate lubrication were causing the failures. NSK propo... Read More
Plate Rolling in Steel Manufacturer Greasing Alternatives - 5219
Viewed 38 time(s) since Jul 30, 2018 - Bearings
A major steel manufacturer was using open roll work bearings in their plate rolling mill. The maintenance team was investigating grease alternatives. NSK was asked to provide a potential alternative for the bearing application with associated cost sa... Read More
Dropping Rollers on Quench Drives - 5218
Viewed 61 time(s) since Jul 30, 2018 - Bearings
A customer was experiencing mechanical failures on quench drives due to wear in the Teflon bushes supporting the quench rollers. This caused the rollers to drop and damage the sprockets and chains, causing the manufactured steel shoe to stick. The re... Read More
Catastrophic Bearing Failure at Ore Preparation Plant - 5217
Viewed 61 time(s) since Jul 30, 2018 - Bearings
A customer was experiencing catastrophic bearings failures in a rotary coal valve within an Ore Preparation Plant. Failures were occurring up to three times in one year resulting in significant lost production and damage to associated components. NSK... Read More
Steel Manufacturer Woes Over Rotary Coal Valve - 5216
Viewed 40 time(s) since Jul 30, 2018 - Bearings
An international steel manufacturer was experiencing bearing failures on a rotary coal valve in their ore preparation plant. Failures were occurring twice per year resulting in significant lost production costs and damage to associated components. An... Read More
Roller Assembly Bearing Failure - 5215
Viewed 66 time(s) since Jul 30, 2018 - Bearings
A customer was experiencing repeated bearing failures fitted to roller assemblies on their wire drawing machinery. The failures were resulting in excessive downtime and high maintenance costs. Management was concerned about the increasing cost. A sol... Read More
Bearing Failure Causing Damage to Final Product - 5214
Viewed 49 time(s) since Jul 30, 2018 - Bearings
A wire manufacturer was experiencing frequent damage on final products due to bearing failures within their wire guides. Deep Groove Ball Bearings were used in the application and were failing on average every 6 weeks resulting in maintenance time an... Read More
Customizing Universal Joints for Metal Processing - 2236
Viewed 250 time(s) since Dec 14, 2016 - Bearings
A high-speed leveling machine that operated with a drive shaft assembly contained a traditional "pin & block" style universal joint. The speed caused the component to overheat posing a fire hazard. See how Belden Universal’s engineering tea... Read More
Formsprag FSR Backstopping Clutch - 1803
Viewed 229 time(s) since Jun 6, 2016 - Clutch and Brake
When the clutch on an older stamping machine required replacement, the retrofit was a Formsprag sleeve-bearing FSR Clutch.See the attachment below for details. Read More
BDI Creates an Application-Specific Pillow Block - 331
Viewed 476 time(s) since Dec 4, 2014 - Bearings
A Northeast Ohio steel mill was using standard cast-iron-housed pillow block bearings on its run-out table. The over spray from an external water bath installed to cool the bearing housing left water spots on the finished product.  The attachment des... Read More
Automatic Lubrication System - 1315
Viewed 766 time(s) since Sep 1, 2015 - Chemicals, Bearings
A Midwestern steel provider had 144 bearings on its sheet leveler that were constantly being over-greased, resulting in blown out seals.It was not effective for the company’s maintenance team to grease the bearings on the sheet leveler because ... Read More
BDI is "Go-To" for Hard-to-Find Swivel Joints - 1238
Viewed 298 time(s) since Jul 16, 2015 - Sealing Devices
While performing an inspection at a steel industry customer location, BDI noticed swivel joints spilling water in the mill. On closer look, we discovered that water was bypassing the top and bottom swivel joints at both ends of the mill, where they a... Read More
Custom-Built Pneumatic Actuator System Eliminates Problem at Tubular Steel Products Plant - 354
Viewed 283 time(s) since Dec 4, 2014 - Pneumatic - Hydraulic
A BDI steel plant customer was purchasing 10-12 electromechanical actuators each month for its cassette lifter.  The hooks moved by the actuators were hitting the cassette, resulting in a shock load that would break the actuators. When this occurred,... Read More
Large Gearboxes Require Maintenance and Lubrication - 1153
Viewed 379 time(s) since Jun 8, 2015 - Mechanical Power Transmission
A gearbox uses mechanical advantage to increase output torque and reduce RPM. A motor's shaft is fed into the gearbox and through a series of internal gears, providing torque and speed conversion. Gearboxes are available in a variety of sizes an... Read More
Custom Fabrication - 272
Viewed 1050 time(s) since Nov 10, 2014 - Automation
A vending machine manufacturer was eager to adopt Lean principles in order to improve plant processes.One procedure under review was the stamping of a metal sheet approximately 4' x 3'. The process required two people to lift, flip and rota... Read More